Software Operational Manual - Dold Mechatronik · EM Series Stepper Drive Software Operational Manual SW-EM-R20111026 1 Introduction The ProTuner is a software tool designed to configure

Software Operational Manual for EM Series Stepper Drives

www.leadshine.com

SM-EM-R20151210

http://www.leadshine.com

ii

SM-EM-R20111026

Leadshine reserves the right to make changes without further notice to any products

herein to improve reliability, function or design. Leadshine does not assume any

liability arising out of the application or use of any product or circuit described

herein; neither does it convey any license under its patent rights of others.

Leadshine’s general policy does not recommend the use of its products in life

support or aircraft applications wherein a failure or malfunction of the product may

directly threaten life or injury. According to Leadshine’s terms and conditions of

sales, the user of Leadshine’s products in life support or aircraft applications

assumes all risks of such use and indemnifies Leadshine against all damages.

©2011 by Leadshine Technology, All Rights Reserved

Change Log

Revision Date Changes Version

2011-10-26 Original Create SM-EM-R20111026

2015-12-10 Description for Alarm Signal. SM-EM-R20151210

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SM-EM-R20111026

Table of Contents Table of Contents ................................................................................................................................................... iii Introduction .............................................................................................................................................................. 1 Workspace ................................................................................................................................................................ 1

Menus and Toolbar .................................................................................................................................... 1 Using the Software ................................................................................................................................................... 3

Opening a file ................................................................................................................................................... 3 Save a file ......................................................................................................................................................... 3 Save as a file ..................................................................................................................................................... 3 Close ................................................................................................................................................................ 3 Connecting Drive .............................................................................................................................................. 3 Current Loop Tuning Window ........................................................................................................................... 4 Properties - Input/Output Settings ...................................................................................................................... 5 Properties - Enable/Disable Features ................................................................................................................. 7 Built-in Controller for Self-test .......................................................................................................................... 8 Error Log Window .......................................................................................................................................... 10 PIN Management Window .............................................................................................................................. 10

Configuring the Drive .............................................................................................................................................. 11 Set Input/Output Parameters ............................................................................................................................. 11 Current Loop Tuning ....................................................................................................................................... 12 Anti-resonance Tuning .................................................................................................................................... 18 Adjusting Electronic Damping ........................................................................................................................ 18

Contact Us .............................................................................................................................................................. 19

EM Series Stepper Drive Software Operational Manual

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Introduction The ProTuner is a software tool designed to configure and tune the Leadshine EM series digital stepper drives include EM402, EM503,

EM705 and EM806. The user can configure the drive’s output current, micro step, electronic damping, command type, tune the current

loop and adjust the anti-resonance parameters in this software.

Workspace

Menus and Toolbar Menus and toolbars are at the top of the workspace. You can click menu bar to view pull-down menu. The toolbar below offers the most

frequency used commands.

Menu

Toolbar

Properties

Window


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Menu Pull Down Toolbar Function

File ->

Open

Open a file

Save

Save a file

Save As - Save as a file

Close - Close the current file

Exit - Exit from the software

Drive ->

Connect To Drive - Connect to drive

Current Loop

Configure current loop parameters Kp and Ki.

Properties

Set drive properties like output current, Micro Step,

command type, electronic damping and active edge.

Build-in Generator

Configure the built-in pulse generator which is used

for anti-resonance tuning and self-test.

Download to Drive - Download data to drive

Reset Drive - Reset drive to factory setting

Tools-> Error Log

Check the drive error log.

PIN Management - Change the drive’s PIN

Help->

Hardware Manual on Web - Click to view EM drives hardware installation manual.

Software Manual on Web - Click to view EM drives software operational manual.

Leadshine Home Page - Click to visit Leadshine Home Page

About Leadshine ProTuner - Software Information


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Using the Software

Opening a file

If you want to load the configuration data from a file in the PC, click on the File->Open. The parameters in the software’s workspace

will be updated. The file name will appear in the tile bar.

Save a file

Click Drive->Save to save the data of current workspace to the open file. If there is no file opened, the Save Dialog appears and you can

type in the file name then save it.

Save as a file

Click Drive->Save As to save the data in current workspace to a file and rename it.

Close

Click Drive->Close to close the current file.

Connecting Drive

Connect to Drive window appears every time you open ProTuner. You can also open it by clicking Drive->Connect any time. Select

the serial port and click on the Connect button. The software will try to connect to the drive and read the settings. It may take several

minutes. Please wait.

File Name


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!Notice

Before connecting the drive, please make sure:

1) The RS232 cable .has been connected between the drive and PC serial port.

2) Power has been applied to the drive and the green LED is turned on.

The motor is no need to connect to the drive if you just want to change the parameters but not tuning.

!Caution

Do not connect or disconnect serial cable when drive is powered on. The drive’s communication circuit may be damaged.

Current Loop Tuning Window

Click Drive->Current Loop to open the current loop tuning window. You can adjust the Kp (proportional gain) and Ki (integral gain) in

this window. These parameters should be tuned before normal operation.

Item Description Range

Kp

(Proportional Gain)

Increase Kp to make current rise fast. Proportional Gain determines the

response of the drive to current setting command. Low Proportional

Gain provides a stable system (doesn’t oscillate), has low stiffness, and

large current error, causing poor performances in tracking current

setting command in each step. Too large Proportional Gain values will

cause oscillations and unstable systems.

1 – 65535

Red Curve:

Target Current of Step Test

Green Curve:

Actual Current of Step Test


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Ki

(Integral Gain)

Adjust Ki to reduce the steady error. Integral Gain helps the drive to

overcome static current errors. A low or zero value for the Integral Gain

may have current errors at rest. Increasing the Integral Gain can reduce

the error. If the Integral Gain is too large, the systems may “hunt”

(oscillate) about the desired position.

1 – 65535

Test Current The current amplitude for the step response. Let this value not exceed

the maximum output current of the drive.

EM402: 0.5 – 2.2A

EM503: 0.5 – 4.2A

EM705:: 0.5 – 7.0A

EM806:: 0.5 – 8.2A

Manual Tuning

Enter Kp and Ki and click this button to activate the test. A target curve

(red) and an actual curve (green) will be displayed on the screen for user

analysis.

-

Self-test and

Auto-configuration

Click this button to activate self-test and auto-configuration. The Kp

and Ki will be tuned automatically. -

Properties - Input/Output Settings

Click Drive->Properties to open the Properties window. In the Input/Output Settings Tab, the user can set Output Current, Micro

Step, Idle Current, Electronic Damping, Pulse Active Edge and Command Type.

!Notice

1. DIP switch must be in Default mode (SW1, 2 for EM402 and SW1, 2, 3 for the others) to allow current change.

2. DIP switch must be in Default mode (SW4, 5 for EM402, SW5, 6, 7, 8 for EM503 and EM705, SW5, 6, 7 for

EM806) to allow Micro Step change.


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Output Current

Drive’s output current for the motor. It should be less than 1.4 times of the motor’s RMS current/phase. Note: The DIP switch setting must be in default mode as follows to be configured by software. EM402: SW1 = on, SW2 = on EM503, EM705, EM806: SW1 = on, SW2 = on, SW3 = on

EM402: 0.07-2.2A EM503: 0.21-4.2A EM705: 0.35-7.0A EM806: 0.35-8.2A

Micro Step

Drive’s Micro Step setting for the motor. Note: The DIP switch setting must be in Default mode as follows to be configured by software. EM402: SW4= on, SW5 = on EM503, EM705: SW5 = on, SW6 = on, SW7 = on, SW8=on EM806: SW5 = on, SW6 = on, SW7 = on

1-512

Idle Current Idle current at motor stop. The drive goes into idle state when there is no pulse applied to it and the DIP SW3 (EM402), SW4 (The others) is set to OFF.

10%-100%

Idle Start Time The time when there is no pulse applied to the drive. The drive goes into idle state after this time.

1-5S

Electronic Damping Adjust this parameter to improve the drive’s high speed performance. The optimal value depends on the system.

1-6000

Command Type

Command Type or pulse mode of control signal. Select PUL/DIR or CW/CCW according to command type of motion controller. PUL/DIR means pulse and direction mode; CW/CCW means double pulses mode. (Note: The EM402 and EM806 only support step & direction command.)

PUL/DIR CW/CCW

Active Edge Pulse active edge. The motor shaft moves one micro step every active edge.

Rising /Following

Direction Change Change the motor direction. It is only active in PUL/DIR command mode. Please note that the actual direction is also related to the motor coil connection.

(High)Positive /(Low)Negative

Alarm Signal

Set active impedance for the alarm (fault) signal. Active High means high output impedance for drive error and Active Low means low output impedance for driver error. (Note: The Alarm Signal of the EM503 and EM705 can not be configured, fixed at Active Low.)

Active Low /Active High

Apply Apply Button. Click this button to apply all the changes. -


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Properties - Enable/Disable Features

This window offers options of enabling phase error detection, motor stall detection and pulse filter. You can also set the active signal of

the enable signal and use it for drive reset to clear the error.

Item Description

Phase Error Detection

Check it to enable phase error detection which is activated when motor

connection is wrong or one of the motor lead is disconnected. The alarm/fault

output will be active if it is enabled.

Sensorless Stall Detection Check it to enable motor stall detection without sensor. The alarm/fault output

will be active if it is enabled.

ENA to Reset the Drive Check it to let the enable signal to reset the drive which is in error state. The

drive will restart and all the error will be clear.

ENA Active High Check it to set the active high for ENABLE signal.

Pulse Filter Enable Check it to enable the pulse filter which smooth the command input.


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Built-in Controller for Self-test

You can adjust the anti-resonance parameters in this window. The built-in controller can be used for anti-resonance tuning and self test.


The 1st Resonance Area It is usually between 0.6 to 1.2 RPS. -

Amplitude 1

Amplitude adjustment for the 1st anti-resonance area. The user can enter a

value directly in the text box or move the slider bar back and forth to get

an optimum value.

0 – 3500

Phase 1

Phase adjustment for the 1st anti-resonance area. The user can enter a


an optimum value.

0 – 1608

The 2nd Resonance Area It is usually between 1.2 to 2.4 RPS. -

Amplitude 2

Amplitude adjustment for the 2nd anti-resonance area. The user can enter a


an optimum value.

0 – 3500


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Phase 2

Phase adjustment for the 2nd anti-resonance area. The user can enter a


an optimum value.

0 – 1608

The 3rd Resonance Area It is usually between 2.4 to 4.8 RPS. -

Amplitude 3

Amplitude adjustment for the 3rd anti-resonance area. The user can enter a


an optimum value.

0 – 256

Phase 3

Phase adjustment for the 3rd anti-resonance area. The user can enter a


an optimum value.

0 – 256

Speed Display the current speed when you move the slider. 0-20 RPS

Acceleration Acceleration of Built-in Controller. 1-65535

Interval Time Interval between the positive and negative move. 1-65535

Repeat Repeat times. 1-65535

Motor Moving Direction

If it is positive, the motor moves only in positive direction. If it is

positive and negative, the motor moves in both positive and negative

direction.

-

Start Click to start the motion.


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Error Log Window

Click Tool->Error Log to open the error log window. This window shows both the present status of each error event and their history.

Item Description

Over Current The motor coil current exceeds the output limit of the drive.

Over Voltage The input voltage exceeds the input limit of the drive.

Phase Error Wrong motor coil connection or one of the motor lead is disconnected.

Stall The motor has been stalled.

Clear All Errors Clear the error log.

PIN Management Window

Every EM drive has a 4-digit PIN (Personal Identification Number). The default PIN is 0000. If you don’t want the drive’s configuration

from read by others, set or change the PIN number in this window. Next time the software communicates with the drive, it requires the

operator to enter the PIN number. If you forget the PIN, the only way to communicate with the drive again is resetting the drive by

clicking Drive->Rreset Drive. The PIN will be 0000 again and all the data is reset to factory setting.


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Configuring the Drive If it is the first time setup, you can follow the steps below to configure the drive.

1) Set Input/Output parameters like output current, Micro Step and command type according to the motor and application.

2) Tune the current loop parameters with the connected motor.

3) Tune the anti-resonance parameters if necessary.

4) Adjust the electronic damping when the high speed performance is not good.

!Notice

The motor must be connected to the drive before trying to configure the drive.

Set Input/Output Parameters

Click Drive->Properties to open the Property window. You can set the Output Current, Micro Step and Command Type.

In most of the application, it is required to set only the output current, Micro Step and Command. Usually, the motor manufacturer states

the RMS (root mean square) current in datasheet. Please refer to the hardware installation manual for how to set the output current.

!Notice

1. DIP switch must be in Default mode (SW1, 2, for EM402 and SW1, 2, 3 for the others) to allow current change.

2. DIP switch must be in Default mode (SW4, 5 for EM402, SW5, 6, 7, 8 for EM503 and EM705, SW5, 6, 7 for

EM806) to allow Micro Step change.

3. The EM402 and EM806 only support step & direction command.

High resolution Micro Step makes the motor move more smoothly. Low Micro Step resolution reduces the high frequency requirement

to the controller. See the EM drives hardware installation manual for more information for how to select the Micro Step.


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Current Loop Tuning

The current loop parameter needs to be tuned before normal for optimize responses with different motors. Otherwise motor will be

easily stalled or howls at power-up. Below is the tuning process of EM705 for a NEMA 23 motor with 24VDC supply voltage.

!Notice

Before trying to tune the current loop parameters, select “custom” in the motor selection table for the rotation switch.

Please note that change of motor requires re-power of drive.

Step 1: Set Test Current 0.5 and start the tuning with small Kp and “zero” Ki. Here we set Kp=500 and Ki=1.

Step 2: Click the Test button and the plot window will show two curves. The red curve is target current and the green curve is actual current. There is large gap between them in the scope. It indicates that a large Kp needs to be introduced.

Initial Value

Kp = 500

Ki =1

Start Test:

Kp = 500

Ki = 1


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Step 3: Increase Kp to 1000 and click Start. The gap between target value and actual value is smaller but a higher Kp is still needed.

Step 3: Give Kp 2000, 3000, 4000 and click Manual Tuning, respectively. The green curve is getting more and more close to the red curve. Over-shoot is obvious when we increase Kp to 4000. It indicates that you need to stop increasing Kp and back off. Our purpose is

to make the green curve (the actual current) a little higher than the red curve (the target). So we decrease Kp to 3700 until the actual

value is exactly over the target value.

↑ Proportional Gain:

Kp = 1000

Ki = 1


Kp =2000

Ki = 1


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Kp = 3000

Ki = 1


Kp =4000

Ki = 1 Over-Shoot

↓ Proportional Gain:

Kp =3700

Ki = 1


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Step 4: Now the Kp is relatively good enough. But there is still gap between the green curve and the red curve when we use the mouse to zoom in the green curve. So we need to introduce Ki to reduce the “gap” or steady error at the constant part. It follows the same

procedure as Kp. High Ki causes big vibration, system lag and makes the performance worse. The following figures show how to tune

the integral gain.

Zero Integral Gain:

Kp =3700

Ki = 1

Drag a triangle to zoom in


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Step 5: The current loop tuning is basically finished. You can continue to adjust Kp and Ki for better performance. Now the updated Kp and Ki is just stored in the driver’s RAM. They will be lost when we power off the driver. Don’t forget to click Drive->Download

To Drive to store the changed value to the drive’s EEPROM.

↑Integral Gain:

Kp =3700

Ki = 200

↑Integral Gain:

Kp =3700

Ki = 400


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Further Adjustment:

Kp =3500

Ki = 300

Save all the changes to the drive’s

non-violated nonvolatile memory.

You need to close the current tuning

window firstly.


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Anti-resonance Tuning

Stepper motors are highly resonant, which results in vibration and ringing. The ringing utilizes a large fraction of the motor's available

torque – thereby wasting performance. Furthermore, at mid-range velocities, the resonance can become so severe that the motor looses

synchronization and stalls. The EM drive provides robust anti-resonance control to stop the vibrations and maintain equilibrium. This

feature requires that the drive be configured with respect to the total inertia in the system. If set improperly, the effectiveness of the

feature may be diminished.

!Notice

1. For most of the application, it is not needed to tune EM drive anti-resonance parameters. We only recommend the

advance user to use this function as it is a boring process.

2. In most of the case, only the tuning of the 1st and 2nd anti-resonance area has obvious effect.

Step 1: Start the motion test by clicking Start/Stop button. Find a resonance speed by slightly moving the slider bar of internal pulse

generator back and forth. You can also use the arrow keys to adjust the speed precisely.

Step 2: Run the motor at the resonance speed and verify the motor smoothness. You may find a better smoothing value by slightly

moving the slider bars of Amplitude and Phase back and forth.

It is very important to make the Amplitude and Phase adjustments at the proper test speeds with an unloaded motor. Running at an

incorrect test speed will not excite the motor at its peak resonance, making it more difficult to find proper adjustment values. Optimum

Amplitude and Phase values may be a little different between running the tests with an unloaded motor and a load motor.

Step 3: Keep the motor running at the resonance speed and verify the motor smoothness. You may find a better smoothing value by slightly moving the slider bars of Amplitude and Phase back and forth. If the motor speed is 0.6-1.2RPS, you should tune the Amplitude

and Phase at the 1st resonance area. The 2nd resonance area is 1.2-2.4 RPS and the 3rd resonance area is 2.4 4.8 RPS.

For example, we find a resonance speed at 0.98 rps. We begin to move the Amp1 slider forth and the motor vibration and noise became

lower and lower. Finally we find the move is the smoothest when Amplitude 1 is 3300. The motor vibration and noise increase if

Amplitude 1 exceeds 3300. Then we follow the same procedure to search the best point for Phase 1. See Figure 26. Anti-resonance

tuning is done.

Step 4: Click Drive->Download To Drive to save all the parameters to EM drive’s nonvolatile memory.

Adjusting Electronic Damping

The factory setting for the electronic damping is 1000. If the motor is easily stalled and generates odd noise at middle speed, you can try

other values such as 500, 1500, 2000, 2500.


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Contact Us China Headquarters

Address: Floor 11, Block A3, iPark 1001 Xueyuan Blvd., Nanshan District, Shenzhen, Guangdong, China

Web: http://www.leadshine.com

Sales Hot Line:

Tel: 86-755-2641-7674 (for Asia, Australia, Africa areas)

86-755-2640-9254 (for Europe areas)

86-755-2641-7617 (for Europe areas)

Fax: 86-755-2640-2718

Email: [email protected].

Technical Support:

Tel: 86-755-2641-8447, 86-755-2641-8774, 86-755-2641-0546

Fax: 86-755-2640-2718

Email: [email protected](for All)

Leadshine U.S.A

Address: 25 Mauchly, Suite 318 Irvine, California 92618

Tel: 1-949-608-7270

Fax: 1-949-608-7298

Web: http://www.leadshineUSA.com

Email: [email protected] and [email protected].
http://www.leadshine.commailto:[email protected]:[email protected](forhttp://www.leadshineUSA.commailto:[email protected]:[email protected]

Documents

Software Operational Manual - Dold Mechatronik · EM Series Stepper Drive Software Operational Manual SW-EM-R20111026 1 Introduction The ProTuner is a software tool designed to configure